Method and apparatus for producing pile fabric

ABSTRACT

Method and apparatus for producing pile fabric comprising pile yarns bonded to a backing material. Lengths of yarn of about twice the pile height are cut off from supply rolls and then folded in half about the slats of a roller carrying such slats in peripherally spaced relationship. The roller is incrementally rotated in contact with a supply of backing material advanced in step with said roller, and to which the fold zones of the yarns are successively bonded. Means are provided for holding pieces of yarn on a slat and folding them in half upon it.

United States Patent [191 Campman 5 1 Dec. 24, 1974 METHOD AND APPARATUS FOR PRODUCING PlllLE FABRIC 21 App]. No.: 353,968

[30] Foreign Application Priority Data 5/1938 Smith 156/435 2,588,130 3/1952 Lemon et a1 156/72 3,347,731 10/1967 Luthy 156/435 3,387,577 6/1968 Spanel et al. u, 156/72 FOREIGN PATENTS OR APPLICATIONS 446,267 4/1936 Great Britain 156/435 Primary Examiner-Daniel J. Fritsch Attorney, Agent, or Firm-Amster & Rothstein [5 7] ABSTRACT Method and apparatus for producing pile fabric comprising pile yarns bonded to a backing material. Lengths of yarn of about twice the pile height are cut off from supply rolls and then folded in half about the slats of a roller carrying such slats in peripherally spaced relationship. The roller is incrementally r0- tated in contact with a supply of backing material advanced in step with said roller, and to which the fold zones of the yarns are successively bonded. Means are provided for holding pieces of yarn on a slat and folding them in half upon it.

6 Claims, 8 Drawing Figures PATENTEUDEBZMHH SHEET 1 or 5 EUR PATEWED 4 3,856.59?

SHEET 3 or 3 1 f 6 (L FIGS 33 QQE M1 L2 L1 FIGS H Hi m H67 W F168 f}? yq/ METHOD AND APPARATUS FOR PRODUCING FILE FABRIC This invention relates to a method of, and apparatus for, making a pile fabric such as carpeting and rugs.

In a well-known method use is made of a rotary roller provided with slat-like members spaced about its periphery. Yarn is supplied from supply rolls and passed to the slat-like members, at which folding means fold portions of the yarn around and between the slat-like members. A carpet backing material is supplied to move along with the other circumference of the roller together with an adhesive and is pressed against the fold zone of the yarn portions folded around the slatlike members whereby the backing and the pile yarns are bonded together.

In a carpet produced by this prior method, the piles form interconnected loops, so that the carpet has the appearance of a looped fabric with ribs of loops.

It is an object of the present invention to provide a method and apparatus for making a pile fabric of the above kind, in which free ends can'be given to the pile of the carpet, said method being reliable and adaptable to various requirements.

According to one aspect of the present invention, there is provided a method for making a pile fabric in which the pile consists of pile yarns bonded to a backing material, said pile yarns being portions of yarns supplied by feeding means from a plurality of supply rolls to a rotatable roller provided with peripherally spaced slats, and in which said yarn portions are folded about the slats by folding means, said backing material is fed along with the circumference of said roller and pressed together with adhesive against the fold zone of the yarn portions folded about said slats to effect bonding between said backing and said pile yarns, characterized by the improvement which consists in first cutting said yarn portions from said yarns and then folding them about said slats.

According to another aspect of the present invention there is provided an apparatus for use in producing a pile fabric, comprising a rotatable roller having peripherally spaced slats, feeding means for feeding yarns from supply rolls to said roller, folding means for repeatedly folding yarn portions about a slat, transport means for supplying a backing material against the circumference of said roller and for causing said backing to run along with said circumference, and characterized by cutting means arranged to cut yarn portions from the leading ends of said yarns and a fork member arranged for reciprocating movement towards and away from said roller for its two fork legs to engage on opposite sides of a slat, there being arranged between said fork legs a clamping member reciprocable under a spring load relatively to said fork member to clamp the cutoff yarn portions on the upper edge of the respective slats during the reciprocating movement of said fork member.

Other features of the invention will become apparent from the following description of two embodiments of apparatus for carrying out the method according to the invention, with reference to the accompanying drawings. in which FIG. I is a schematic sideview of a first embodiment of an apparatus according to the invention;

FIG. 2 illustrates part of the showing of FIG. I, but depicts the vital parts of the apparatus in a different position;

FIG. 3 is an axial cross-section of the folding and clamping means shown in FIG. 1 and 2, but on a larger scale;

FIG. 4 is a bottom view according to the arrow IV of FIG. 3;

FIG. 5-8 illustrate schematically a second embodiment of the apparatus according to the invention, showing its vital parts insuccessive stages of operation.

Referring to FIG. 1, there is shown a roller ll provided with upright slat-like members 2, hereinafter referred to as slats. Roller 1 has a length at least equal to the breadth of a carpet 3 to be made, and is mounted for rotation in a frame (not shown). Mounted in the same frame is a swivel shaft 4, extending likewise over the entire width of the frame and parallel to roller 1. Shaft 4 carries at least one pair of tongs 6, which it can swivel back and forth over substantially 180. Independently of that movement, shaft 4 can perform a reciprocating lateral movement as indicated by double arrow Provided on the side of shaft 4 remote from roller 1 is a supply roll 7 of yarn 8. The yarn is passed through a yarn carrier 9, a passage opening 10 of which is provided with a clamping spring 11, which arrangement is well-known in the art. Arranged between yarn carrier 9 and shaft 4 is a cutter 12, comprising a pair of blades between which the yarn is passed.

Mounted at the top of roller 1 is a yarn clamping and folding device 13, comprising a casing 14 in which a clamping die 16 is slidably arranged (also see FIG. 3 and 4). At the bottom end of casing 14 is a bifurcated member or fork 17 which together with casing 14 can be moved up and down as indicated by the double arrow 25. The legs 18 of bifurcated member or fork 17 may consist of sheets extending over the entire length of roller 1, said legs 18 being spaced and dimensioned so that they can move on opposite sides along a slat 2. Die 16 has a recess 34 at its bottom end, formed to slightly enclose the upper edge of a slat when coming into engagement with it.

Mounted for reciprocating rotation on the side of yarn clamping and folding device 13 away from shaft 4 is a shaft I9, which is likewise supported in the frame not shown, and like shaft 4 extends the full length of roller 1. Shaft 19 carries a series of fingers 21, one end of which can be moved by shaft 19 into and out of engagement with the upper end of a slat 2.

A drum 23, supported in the frame not shown carries a roll of carpet backing 24, which via guide rollers 26 and 27 is guided against the outer circumference of roller l, the arrangement being such that backing 24 follows the intermittent movement of roller 1, at the same rate. Before backing 24 comes into contact with roller ll, adhesive 31 is applied to the backing. by means of a dispenser 29. After leaving guide roller 27, backing 24, provided with pile yarns bonded thereto is rolled up on a drum 28.

The operation of the apparatus described above is as simultaneously performed a translatory movement to the right (as seen in the drawing) for tongs 6 to grip the leading end of yarn 8 extending through aperture 10 of yarn carrier 9. Thereafter shaft 4 has been driven to move tongs 6 to the left, which is the position shown in FIG. 2. g

The respective drive mechanisms for the reciprocating rotation and translation of shaft 4 and for opening and closing tongs 6 in synchronism therewith are not described herein in detail, as these drive mechanisms can be implemented by conventional constructional means As soon as tongs 6 have closed to grip the leading end of yarn 8 and subsequently shaft 4 has moved to the left (as seen in the drawing) by a distance corresponding to twice the pile height, cutter 12 is operated to cut off a piece of yarn 33 of twice the pile height, which piece of yarn 33 is moved by an anti-clockwise swiveling movement through about 180 to a position over the stationary slat 32. During this swiveling movement of tongs 6, yarn clamping and folding device 13 is in a higher position than is shown in FIG. 1 to allow the passageof the piece of yarn 33. Tongs 6 are now opened and device 13 is moved downwards (also see FIG. 3) for clamping die 16 to clamp the piece of yarn 33 on the upper edge of slat 32 with its recess 34. The downward movement of device 13 is continued, whereby the legs 18 of fork 17 move on opposite sides along the slat, folding the ends of the piece of yarn 33 about slat 32. This creates the situation as shown for slat 36 in FIG. 1, which has a piece of yarn, designated 37, folded about it.

During the folding operation of legs 18, die 16 continues to clamp yarn 33, which arrangement will be described in more detail with reference to FIG. 3.

Referring to FIG. 3, there is shown how clamping die 16 can move relatively to casing 14 against the action ofa helical spring 38. During the downward movement of device 13, as described above, when the folding legs 18 move on opposite sides of slat 32, die 16 is retained by slat 32 and clamps the fold zone of the piece of yarn 33 on to slat 32. During these movements of yarn folding and clamping device 13, tongs 6 have been swiveled back into position for gripping a pile yarn 8.

Roller I is now rotated to bring the next slat under device 13, and the process is repeated as described. When a folded pile yarn has arrived in the position shown in FIG. 1, such as yarn 36 folded about slat 37, finger 21 is lowered on to the fold zone of yarn 36 to prevent the latter from being dislodged by leg 18 during its upward movement. When roller 1 rotates finger 21 is in a raised position.

Backing material 24 is provided with a layer of adhesive 31 when passing dispenser 29. This layer of adhesive is contacted with the fold zones of the pile yarns in the nip formed between the tops of the slats and roller 26. In the path between guide rollers 26 and 27 the adhesive is allowed to set, so that the pile is bonded to the backing, and the ready carpet can be wound on to drum 28 via guide roller 27.

FIG. 5-8 show a modified embodiment of the yarn clamping and folding means according to the invention. As shown. the folding means comprises a single folding leg 41 movable up and down, and the clamping means is an element 42 extending tangentially to the circumference of roller 1 and movable back and forth in the tangential direction. In this embodiment tongs 6 also perform the function of a clamping means, since the trailing end of the piece of yarn is being retained by tongs 6 during the folding operation.

The operation of this embodiment is as follows:

When tongs 6 have moved a piece of yarn 33 over slat 32 theycontinue to hold the yarn while folding leg 41 is lowered to fold the leading end of the yarn (on the left in the drawing) against one side of slat 32. The yarn is then released by tongs 6; folding leg 41 is moved upwards to release slat 32 (FIG. 7); and roller 1 is rotated in increment equal to the distance between two adjacent slats. Element 42 is now moved to the right to maintain yarn 33 clamped on slat 32. Meanwhile tongs 6 have moved a next piece of yarn 39, cut to length, over slat 43(FIG. 7). Folding leg 41 is again moved downwards and presses the overlapping ends of yarn 33 and 39 jointly into the interspace between slats 32 and 43 (FIG. 8). Subsequently folding leg 41 is moved upwards, element 42 is. moved to the left, roller 1 is rotated one increment further, and tongs 6 are swiveled clockwise in position to grip a new piece of yarn, whereafter the cycle is repeated.

Other modifications will readily occur to those skilled in the art without departing from the scope of the present invention. Thus instead of a single sheetlike die 16 in certain cases a series of narrower dies may be used, which extend over the entire width of roller 1, or instead of fingers 21 a plate may be employed, extending throughout the width of roller 1. Furthermore adhesive may be applied to the fold zones of the pile yarns as they move towards guide roller 26, either in addition to, or instead of, the adhesive applied to the backing. It is also possible to use a backing provided elsewhere with a bonding component reacting through the application of heat and/or pressure or reacting with a second component. Also, the invention is not limited to the use of yarns, but is equally applicable to fabrics in which the pile consists of webbing.

Furthermore in certain cases the method of the present invention can be carried out in apparatus of the first embodiment hereinbefore described, but omitting die 16 and/or finger 21. This possibility depends on the nature of the pile material used, namely, if it has little tendency to become dislodged on a slat once it has been folded around it.

I claim:

1. Apparatus for use in producing a pile fabric wherein the pile has a predetermined height comprising a roller rotated intermittently and having a plurality of peripherally located, spaced radially extending slats;

yarn supply means;

cutting means associated with said yarn supply means to cut off pieces of yarn, the length of each piece being equal to twice the pile height;

pivotal means capable of grasping the individual cut yarns and transporting said yarns by pivotal movement to said slats;

reciprocating means located adjacent said roller;

21 receiving area located between said reciprocating means and said slats, said yarn pieces being transported to said receiving area by said pivotal means;

said reciprocating means having leg means movable into said receiving area to fold center portions of individual yarn pieces respectively about ends of succeeding slats during a stationary part of said intermittent rotation;

movable holding means located adjacent said receiving area and adapted to contact the individual ends of said slats over which said individual yarn pieces have been folded, said contact taking place when said roller is stationary, and said holding means being mounted to be movable out of contact therewith when said roller is subjected to said intermittent rotation; and

carpet'backin'g means located adjacent said roller and adapted to feed backing material into adhering association with said folded yarn pieces. 2. Apparatus according to claim 1 wherein said movable holding means are defined as finger means that are pivotally mounted to be rotatable out of contact with the individual ends of said slats.

3. Apparatus according to claim 1 wherein said movable holding means are mounted to be reciprocable in a direction tangential to the individual ends of said slats in said receiving area.

4. Method of making a pile fabric wherein the pile has a predetermined height comprising providing a continuous supply of yarn;

cutting the yarn into individual pieces each of a size double the pile height;

6 v grasping individual pieces and positioning them respectively in a receiving area atop ends of radial slats in an intermittently rotating roller;

passing leg means between the slats in the receiving area to fold an individual yarn piece about one of the slats while simultaneously applying a holding pressure to an individual yarn piece previously folded about an adjacent slat while said roller is stationary;

removing said holding pressure and leg means while the roller is subjected to the intermittent rotation; and

applying carpet backing material into adhering association with the folded individual yarn pieces.

5. Method according to claim 4 wherein said holding pressure is supplied intermittently by rotating finger means into and out of engagement with the individual yarn pieces folded on the endsof the slats.

6. Method according to claim 4 wherein said holding 

1. Apparatus for use in producing a pile fabric wherein the pile has a predetermined height comprising a roller rotated intermittently and having a plurality of peripherally located, spaced radially extending slats; yarn supply means; cutting means associated with said yarn supply means to cut off pieces of yarn, the length of each piece being equal to twice the pile height; pivotal means capable of grasping the individual cut yarns and transporting said yarns by pivotal movement to said slats; reciprocating means located adjacent said roller; a receiving area located between said reciprocating means and said slats, said yarn pieces being transported to said receiving area by said pivotal means; said reciprocating means having leg means movable into said receiving area to fold center portions of individual yarn pieces respectively about ends of succeeding slats during a stationary part of said intermittent rotation; movable holding means located adjacent said receiving area and adapted to contact the individual ends of said slats over which said individual yarn pieces have been folded, said contact taking place when said roller is stationary, and said holding means being mounted to be movable out of contact therewith when said roller is subjected to said intermittent rotation; and carpet backing means located adjacent said roller and adapted to feed backing material into adhering association with said folded yarn pieces.
 2. Apparatus according to claim 1 wherein said movable holding means are defined as finger means that are pivotally mounted to be rotatable out of contact with the individual ends of said slats.
 3. Apparatus according to claim 1 wherein said movable holding means are mounted to be reciprocable in a direction tangential to the individual ends of said slats in said receiving area.
 4. Method of making a pile fabric wherein the pile has a predetermined height comprising providing a continuous supply of yarn; cutting the yarn into individual pieces each of a size double the pile height; grasping individual pieces and positioning them respectively in a receiving area atop ends of radial slats in an intermittently rotating roller; passing leg means between thE slats in the receiving area to fold an individual yarn piece about one of the slats while simultaneously applying a holding pressure to an individual yarn piece previously folded about an adjacent slat while said roller is stationary; removing said holding pressure and leg means while the roller is subjected to the intermittent rotation; and applying carpet backing material into adhering association with the folded individual yarn pieces.
 5. Method according to claim 4 wherein said holding pressure is supplied intermittently by rotating finger means into and out of engagement with the individual yarn pieces folded on the ends of the slats.
 6. Method according to claim 4 wherein said holding pressure is supplied intermittently by reciprocating an element tangentially with respect to the ends of the slats in the receiving area. 